cracking noise

[hybridbear]

 

Just wanted to go over all the issues with my car with other owners.

 

 

Car notes

Rear sensor beeps- 2 tones. Sometimes loud and sharp but mostly normal soft.

Build quality exterior- door moldings do not fit well. A lot of gaps and issues.

Rear window - distortion. Dealer replaced and replacement still has distortion.

Lag in sync system and Navi. Changing stations fast causes delay. Navi takes forever sometimes

Phone lag on pickup. Sometimes a few seconds. People hear the ringing while my car try's to connect to my phone.

Filling gas. nozzle doesnt stay. Some gas stations are a pain. I have to hold down the gas nozzle to ensure my car fills. The nozzle will not stay and autofill all the time.

Lack of access to car when battery dies. My battery died once.... you have no way of getting into car unless you call roadside assistance. You cant open doors or the trunk.

Navi screen. Dust and finger print magnet. Cloth only pushes dust into corners. You cant properly clean it with the cloth.

Rattling noise from driver side fender. Was not assembled correctly and took months to track down. Once found the body shop fixed it. But now i am left with a gap between my hood and fender that is not pleasant.

Delay in trunk opening and locking cars doors or unlocking. Even the alarm button when pushed by mistake sometimes takes forever to correct

Sorry about the crude notes. Those are from my phone so i just pasted it into the window. As for the axle popping noises.... i ran into this in December and have been waiting for a fix for months now

I am taking all these notes and some extra ones along with my print outs from my 10 dealership visits to a Ford Event in my state that is taking place on the 17th of this month. I m going to let the engineers have it good. They want to do a sit in with a few ford fusion owners and get feedback about the vehicle.

I wont hold back my frustrations and disappointments at all =].

Sorry for the format of this post. It was done from my phone.

 

I've noticed some delays too like you mention. When unlocking the doors the doors unlock right away but there is about a 1 second delay before the lights flash, this developed after a few thousand miles, at first the lights flashed immediately. The phone lag is also noticeable, but that's what we get since the system was built by Microsoft. Remember: "Microsoft Works is an oxymoron." The gas pumps shutting off is a real pain. I've found that certain pumps at the same gas station have this issue and other pumps at that same gas station do not. This makes me wonder if it isn't a pump issue, but is a car issue and at those times when it does this ANY gas pump anywhere would behave this way. There have been discussions about this in another thread. Our backup sensors also periodically beep at a differnt pitch. Turning the car off and back on makes this go away.

 

The build quality issues and the fender issue are items that your dealer needs to fix. It would be nice to not have such problems from the start, but we all do. Don't let your dealer get away with not fixing those things. Ford will approve the repair if the dealer puts the request through. Some of the door trim panel issues are widespread and the dealers cannot get parts in for them because so many dealers are requesting those parts. One of my door panels that is poorly installed has been backordered for more than 2 months now. After I showed the dealer the gap on my car they looked at the other cars on their lot and realized that almost all of them need to be repaired. Other customers who bought Fusions from them have also complained about this particular gap.

 

Where do you have the opportunity to meet with some Ford engineers? It will be interesting to hear what they have to say overall and what other questions people ask. Please share that with us once you talk to them next Friday.

Edited May 9, 2013 by hybridbear

[neod192]

After I showed the dealer the gap on my car they looked at the other cars on their lot and realized that almost all of them need to be repaired. Other customers who bought Fusions from them have also complained about this particular gap.

Which gap is this? By the A pillar?

[47Minutes]

 

Rear window - distortion. Dealer replaced and replacement still has distortion.

 

I just got mine back from having this same issue looked at. Mine replacement glass too has the distortion. If two, four counting yours, have the distortion, how is it more owners aren't noticing this? Oh, and don't get me started on the interior tear down that has to take place to replace that rear glass. I now have a wrinkle in my headliner to contend with as a result of that.

[chris_spangler]

I definitely have the same distortion issue with my rear window. However, I'm choosing to just accept that as I definitely would rather deal with that than have a technician tear apart the interior and have the interior headliner and pieces never quite fit together the same. I'm more concerned with waiting for the TSB for the cracking noise to be resolved.

[Dan Newman]

I am also hearing the cracking/popping noise on starting or stopping. My dealer told me that it was the regenerative breaks, and was a normal sound (based on my description of the problem, not a test drive), but other hybrids I've driven don't sound like this, and I didn't remember hearing it when we first got the car. The most telling thing to me is that I hear it long after the regenerative breaks have been disengaged, when starting up with a speed around 5mph.

 

So, the million dollar question: do I bring it in, knowing that there's no solution yet, to have the problem recorded? Or do I wait until there's a solution?

[new2fordfusion]

Reg the Cracking Noise.. Yes, we are all waiting for ford fo say what the heck it is and what fix is needed (atleast im waiting). No point taking to the dealer when a few others have tried the same, replacing parts etc and still having issues.

 

I also have the rear glass distortion and its a bit annoying, but wouldn't try to change it considering the amount of teardown required as you guys have called out.

 

The last time I took my car to the dealer to get my exterior rear quarter glass chrome trim fixed, the morons in the dealership put dirty fingers on my headliner in a few places.. I will have to try and get rid of it with magic eraser or something.. ugh

[chris_spangler]

Tough question on bringing it in or not... I would think that your dealership would not be able to resolve similar to all of the rest of the owner's experiences on here so don't expect it to get resolved. On the other hand, the more owners that bring their brand new Fusion Hybrids in with this issue may escalate the issue among Ford engineers to quick get on a resolution before it gets out of hand. The clicking/cracking sound was absolutely not present when I first purchased my car, which would lead anyone to believe it is an issue and one that should be corrected.

[hybridbear]

Which gap is this? By the A pillar?

Left side rear door B pillar. Where the piano black piece meets the door frame there is a couple millimeter gap. All the other panels are snug, but this particular panel has a gap.

 

The last time I took my car to the dealer to get my exterior rear quarter glass chrome trim fixed, the morons in the dealership put dirty fingers on my headliner in a few places.. I will have to try and get rid of it with magic eraser or something.. ugh

You should bring it back and make them fix it. The dealer did the same thing to my headliner when they fixed the rattle it had. I pointed out the stain and they took care of it. They also fully detailed the car inside and out because of the inconvenience their mistake caused me

[erichFla]

I am also hearing the cracking/popping noise on starting or stopping. My dealer told me that it was the regenerative breaks, and was a normal sound (based on my description of the problem, not a test drive), but other hybrids I've driven don't sound like this, and I didn't remember hearing it when we first got the car. The most telling thing to me is that I hear it long after the regenerative breaks have been disengaged, when starting up with a speed around 5mph.

 

So, the million dollar question: do I bring it in, knowing that there's no solution yet, to have the problem recorded? Or do I wait until there's a solution?

 

This is the SAME thing my dealership is telling me, not to worry about it, it's the Brake Relays making the noise but I disagree. Yet they won't test or look at anything but it's in my records now. Can't wait till the TSB comes out.

[expresspotato]

 

This is the SAME thing my dealership is telling me, not to worry about it, it's the Brake Relays making the noise but I disagree. Yet they won't test or look at anything but it's in my records now. Can't wait till the TSB comes out.

Brake relays? There are no such things. The only relay with respect to the HV system is in the trunk, in the battery pack. Everything else is solid state (obviously except for MG1 & MG2).

[erichFla]

That just goes to show they are BS-ing their customers.

[rvlasek]

Anyone received any information concerning crackling noise issue, my dealer has no updates on the hotline assistance number I gave them last week...

[47Minutes]

Mine is back at the dealer for paint work again since last Thursday. They still have no update on mine for the Hotline Assistance number.

[gl419]

I took mine in a couple of weeks ago. They spent 3 days trying to stop the cracking noise. Tightened everything in the front end. No help. Then took off the half shafts and packed with teflon grease and reassembled. At first, for a week or so, the cracking stopped. But now it is starting to come back. It has something to do with the drive shafts, tolerance stack up or something similar. For now I'll wait for the TSB to be issued. I suspect they will have to replace something in the drive shaft system. TIme will tell.

[gkinla]

I took mine in a couple of weeks ago. They spent 3 days trying to stop the cracking noise. Tightened everything in the front end. No help. Then took off the half shafts and packed with teflon grease and reassembled. At first, for a week or so, the cracking stopped. But now it is starting to come back. It has something to do with the drive shafts, tolerance stack up or something similar. For now I'll wait for the TSB to be issued. I suspect they will have to replace something in the drive shaft system. TIme will tell.

Gl419,

 

Deja Vu...after tightening everything then packing the half shafts with grease on my 2013 FFH the noise came back after one week. Brought the 2013 back, the dealer ordered half shafts and replaced them. The noise went away for approx 1200 miles then returned. This was the same miles that I first started hearing/noticing the clicking noise. I think you're right about the tolerance stack up.

[LEM]

hey guys, do you really think this issue will ever be resolved?

I am getting close to buy this car but I see this is a very common issue, and honestly, I don't want to pay a lot of money and have this kind of problem,

especially because there seems not to be explicit feedback from Ford.

 

Thanks.

Edited May 14, 2013 by LEM

[hybridbear]

hey guys, do you really think this issue will ever be resolved?

I am getting close to buy this car but I see this is a very common issue, and honestly, I don't want to pay a lot of money and have this kind of problem,

especially because there seems not to be explicit feedback from Ford.

 

Thanks.

Not all owners have this issue. We have almost 10,000 miles with no cracking noise. There is a thread detailing how many owners do not have the sound. Since not all cars have the issue it should be easier for Ford to identify the problem and get a fix. It seems likely it could be due to bad parts from one of their suppliers leading to this noise.

[hybridbear]

I created a poll to help us get a handle on the data of who has this issue. Please take a few minutes to answer. I'm hoping we'll find some patterns regarding build dates and the noise

[Serraph]

Not sure if this is the right area or not but there are a few MKZ owners that have this issue as well. I'm one of them and this is their 2nd try at attempting to fix the cracking/popping noise. Still waiting for the call to see what they would do next. The car is about 700miles in with 2 attempts. Built in February.

Edited May 14, 2013 by Serraph

[hermans]

Not sure if this is the right area or not but there are a few MKZ owners that have this issue as well. I'm one of them and this is their 2nd try at attempting to fix the cracking/popping noise. Still waiting for the call to see what they would do next. The car is about 700miles in with 2 attempts. Built in February.

What are they trying to fix? Ford doesn't even know what's causing it. Ford has told it's dealers not to spend warranty time on this as they don't have a fix yet.

 

I suspect my MKZ will have the problem just as my '13 FFH does.

[Serraph]

What are they trying to fix? Ford doesn't even know what's causing it. Ford has told it's dealers not to spend warranty time on this as they don't have a fix yet.

 

I suspect my MKZ will have the problem just as my '13 FFH does.

Here is a summary of what they did:

Verify pop/click noise from ft lh side of vehicle when accelerating from a stop, or backing up. used an assistant to aid in diagnosis to pinpoint area of noise. isolated to spindle area on ft lh side. oasis no help. check lugnut torgue, ok at 115lbs, check ft axle nut torque, was less then 150lbs at time of inspections. remove undercarriage splash shields to inspect all mounts hardware unibody like structures for wintness mark concerns for any movement none can be seen. contacted hotline on conditions. used chassie ear to pinpoint area of noise, found noise is loudest at the lh ft spindle/hub. removed ft lh axle from hub to inspect splines and hubs contact points. check for fiber washer, found washer is present and intact behind the hub to cv axle. no problems found with washer at this time. for condition replaced the ft cv axle and the lh ft hub for concern. reassemble with new axle nut, torque all fasteners to specs, recheck for concerns. normal. road test with shop foreman, normal operational noise remain at this time.

 

So far the click/pop has come back after a week of service.

[elle]

Well, I noticed mine beginning to make the ping-pong noise now, at just over 3000 miles. It does sound to me like it is related somehow to the braking, and it sounds like it is coming from the rear of the car. I'm not going to worry about or take it in unless I get better confirmation here that it is not one of the normal pop-whirr-buzz things that are so common with hybrids. I guess I got used to the strange sounds in the Prius because this one is not upsetting me, at least not yet, and since there is no concrete information about it being something that needs to be fixed, there's no point taking it to the dealer.

 

However, I will be checking this thread to see if any additional information comes out. If it is indicative of a problem, I want to know about it!

[Jaw-Knee]

Cracking noise is getting Louder and Much More Annoying! 2300 miles! I'm embarrassed coming to a stop at work! I constantly have to explain what it is, and that Ford "is searching for a fix." If I could take it back, I would in a heartbeat! Not Happy!!!!

[expresspotato]

You know I'm embarrassed too - this has been going on ever since I bought the vehicle.

[basicallyevolve]

Hey guys.

 

I was with a bunch of ford engineers today and they told me they have a fix for the popping axles. They told me to make an appointment with my dealership so they could resolve my issue.

 

I will let you guys know what they do to the vehicle when i get a chance but it may be a few days because i have a lot of issues thT i want them to fix.